U.S. patent application number 11/563804 was filed with the patent office on 2007-04-26 for helmet protection system.
This patent application is currently assigned to Bell Sports, Inc.. Invention is credited to Arne Lang-Ree, Hilgard N. Muller.
Application Number | 20070089218 11/563804 |
Document ID | / |
Family ID | 35755915 |
Filed Date | 2007-04-26 |
United States Patent
Application |
20070089218 |
Kind Code |
A1 |
Lang-Ree; Arne ; et
al. |
April 26, 2007 |
Helmet Protection System
Abstract
According to some embodiments of the invention, a system for
protecting a device formed from polystyrene is provided. The system
includes a body formed from polystyrene. The system also includes a
protective layer formed from thermoplastic elastomer. The
protective layer is coupled to the body during a molding process
used to form the body.
Inventors: |
Lang-Ree; Arne; (Los Gatos,
CA) ; Muller; Hilgard N.; (Felton, CA) |
Correspondence
Address: |
BAKER BOTTS L.L.P.
2001 ROSS AVENUE
SUITE 600
DALLAS
TX
75201-2980
US
|
Assignee: |
Bell Sports, Inc.
Irving
TX
|
Family ID: |
35755915 |
Appl. No.: |
11/563804 |
Filed: |
November 28, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10911243 |
Aug 3, 2004 |
7140049 |
|
|
11563804 |
Nov 28, 2006 |
|
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Current U.S.
Class: |
2/410 |
Current CPC
Class: |
A42C 2/002 20130101;
A42B 3/10 20130101 |
Class at
Publication: |
002/410 |
International
Class: |
A42B 1/06 20060101
A42B001/06 |
Claims
1. (canceled)
2. (canceled)
3. (canceled)
4. (canceled)
5. (canceled)
6. (canceled)
7. (canceled)
8. (canceled)
9. (canceled)
10. (canceled)
11. A method for providing a protective layer, comprising:
providing a clam shell mold defining a chamber; positioning a
protective layer of thermoplastic elastomer in the chamber; after
positioning the protective layer, providing expanded polystyrene in
the chamber; and heating the expanded polystyrene in the
chamber.
12. The method of claim 11, wherein the chamber comprises a shape
of a helmet.
13. The method of claim 11, wherein heating the expanded
polystyrene comprises exposing the expanded polystyrene to
steam.
14. The method of claim 11, wherein providing expanded polystyrene
comprises providing expanded polystyrene so that the protective
layer is disposed on an outer surface of the expanded polystyrene
after the method is complete.
15. The method of claim 11, wherein the chamber comprises a shape
of a helmet having an outer surface, an inner surface, and a rim
portion disposed between the outer surface and the inner surface,
and positioning the protective layer comprises positioning the
protective layer at a portion of the chamber that has a shape of
the rim portion.
16. The method of claim 11, wherein the protective layer is a first
protective layer, and further comprising positioning a second
protective layer of plastic shell in the chamber before providing
the expanded polystyrene.
17. The method of claim 11, wherein the clam shell mold comprises a
first side and a second side, positioning a protective layer
comprises positioning the first protective layer in the first side,
and positioning a second protective layer comprises positioning the
second protective layer of plastic shell in the second side of the
clam shell mold.
Description
TECHNICAL FIELD OF THE INVENTION
[0001] This invention relates generally to protective gear and more
particularly to a helmet protection system.
BACKGROUND OF THE INVENTION
[0002] A physical impact to the head of a person may cause serious
injury or death. To reduce the probability of such consequences,
protective gear, such as a helmet, is often used in activities that
are associated with an increased level of risk for a head injury.
Examples of such activities include, but are not limited to,
skiing, snowboarding, bicycling, rollerblading, rock climbing,
skate boarding, and motorcycling.
SUMMARY OF THE INVENTION
[0003] According to some embodiments of the invention, a system for
protecting a device formed from polystyrene is provided. The system
includes a body formed from polystyrene. The system also includes a
protective layer formed from thermoplastic elastomer. The
protective layer is coupled to the body during a molding process
used to form the body.
[0004] Some embodiments of the invention provide numerous technical
advantages. Other embodiments may realize some, none, or all of
these advantages. For example, according to one embodiment, a
helmet is protected by providing a protective layer over areas of a
helmet body that are likely to be damaged by dropping or use of the
helmet, such as a rim portion of the helmet body. Such protective
layers may be especially advantageous for protecting the softer,
"foam-like" portions of the helmet.
[0005] Other advantages may be readily ascertainable by those
skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Reference is now made to the following description taken in
conjunction with the accompanying drawings, wherein like reference
numbers represent like parts, in which:
[0007] FIG. 1 is a diagram illustrating one embodiment of an
environment in which a helmet may be used;
[0008] FIG. 2 is a schematic diagram illustrating a perspective
view of one embodiment of a protective layer that is disposed over
a rim portion of the helmet shown in FIG. 1;
[0009] FIG. 3 is a schematic diagram illustrating a cross-section
of the helmet and the protective layer shown in FIG. 2; and
[0010] FIG. 4 is a flowchart illustrating one embodiment of a
method for providing the protective layer for the helmet shown in
FIGS. 2 and 3.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION
[0011] Embodiments of the invention are best understood by
referring to FIGS. 1-4 of the drawings, like numerals being used
for like and corresponding parts of the various drawings.
[0012] FIG. 1 is a schematic diagram illustrating one embodiment of
an environment 10 in which a helmet 20 according to one or more
embodiments of the present invention may be used. As shown in FIG.
1, environment 10 includes a bicyclist (user) 12 riding a bicycle
14 and wearing helmet 20 on a head 16 of user 12. Helmet 20
comprises a body 50, a front portion 24, a rear portion 28, a visor
30 coupled to front portion 24, front straps 18F, and rear straps
18R. Helmet 20 is secured to head 16 through the use of front
straps 18F and rear straps 18R, which are collectively referred to
as straps 18. The term "helmet" is used in this document to include
any type of protective head gear, such as a bicycle helmet, a
motorcycle helmet, and a hard hat. Although helmet 20 is used as an
example to describe some embodiments of the present invention, any
type of helmet, both protective and non-protective, may benefit
from the teachings of the present invention. Furthermore, as
described below, embodiments of the present invention may also be
used in conjunction with products other than helmets.
[0013] Referring again to FIG. 1, if user 12 were to accidentally
fall off of bicycle 14, user 12 may suffer various injuries,
including an impact to head 16. Because the use of a protective
head gear such as helmet 20 may reduce the severity of trauma to
head 16 in case of an impact, the use of helmet 20 is strongly
encouraged for many activities where the probability of injury to
head 16 is relatively high.
[0014] A body of a protective headgear, such as helmet 20, is
generally formed from a shock-absorbing material, such as expanded
polystyrene (EPS). The surface of a body formed from EPS may be
easily dented, scratched or otherwise damaged, which may compromise
the ability of the helmet to offer protection against impact and/or
present an unattractive appearance. To protect against such a
damage, a hard plastic shell may be provided over the outer surface
of the helmet body. However, portions of the existing helmet are
not protected with such a shell because of certain manufacturing,
cost, comfort, or other limitations. For example, the bottom rim of
a helmet body may be unprotected.
[0015] According to some embodiments of the present invention, a
system for protecting a helmet from damage is provided by providing
one or more protective layers over portions of a helmet body that
are associated with a relatively high risk of damage, such as a rim
portion of a helmet. This is advantageous because the level of
durability of a helmet is improved while maintaining the capacity
of the helmet to protect the wearer's head. Additional details of
example embodiments of the invention are described below in greater
detail in conjunction with FIGS. 2-4.
[0016] FIG. 2 is a schematic diagram illustrating a perspective
view of helmet 20 that may benefit from the teachings of the
present invention. FIG. 3 is a schematic diagram illustrating a
cross-section of helmet 20 at a phantom line 60 shown in FIG. 2.
Referring to FIG. 2, helmet 20 comprises a body 50, an outer
surface 36, an inner surface 32 that defines a bowl-shaped chamber,
and a rim portion 34 that is disposed between outer surface 36 and
inner surface 32 at the bottom of the helmet. Rim portion 34
comprises a front left rim portion 34FL, a front right rim portion
34FR, a rear left rim portion 34RL, and a rear right rim portion
34RR. Front left rim portion 34FL, front right rim portion 34FR,
rear left rim portion 34RL, and rear right rim portion 34RR may
also be referred to as front left corner portion 34FL, front right
corner portion 34FR, rear left corner portion 34RL, and rear right
corner portion 34RR, respectively. In certain embodiments, although
not explicitly shown in FIG. 2, helmet 20 may comprise ventilation
holes, internal/external support structures, and/or other suitable
components, such as a helmet retention system and a helmet fitting
system.
[0017] Referring to and as shown in FIG. 3, body 50 comprises an
outer surface 24 to which a shell 54 may be coupled. Thus, in
certain embodiments, outer surface 36 of shell 54 constitutes outer
surface 36 of helmet 20. However, where shell 54 is omitted from
helmet 20, outer surface 24 constitutes the outermost surface of
helmet 20. Body 50 may be formed from any suitable material, such
as EPS. Rim portion 34 and inner surface 32 are parts of body 50,
and thus are formed from the same material, such as EPS. Shell 54
may be formed from any suitable material that is operable to resist
damage and wear. An example of such a material includes, but is not
limited to, polycarbonate plastic. Shell 54 may be used to add
color, patterns, pictures, and/or any other suitable design to
helmet 20.
[0018] Referring to FIGS. 2 and 3, according to certain embodiments
of the invention, one or more protective layers 40 may be
positioned over some or all of rim portion 34. This is advantageous
in some embodiments because rim portion 34 is generally impractical
to cover with shell 54 due to manufacturing, cost, comfort, or
other limitations. Protective layer 40 may be formed from a
thermoplastic elastomer (TPE) or any other suitable material. In
some embodiments, protective layer 40 may be formed from a
styrene-based TPE. Using certain types of TPE, such as
styrene-based TPE, to form protective layer 40 is advantageous in
some embodiments where body 50 of helmet 20 is molded out of EPS
because such protective layer 40 can be in-molded with body 50 and
also adheres well to EPS. However, embodiments using other types of
TPE, including olefin-based TPE, are also envisioned. In certain
embodiments, protective layer 40 may cover certain portions (or
all) of outer surface 24 of body 50 that are not covered by shell
54. In certain embodiments, protective layer 40 may overlap shell
54. Although rim portion 34 is used as an example area of body 50
that may be protected by protective layer 40, any area of body 50
of helmet 20 where body 50 is exposed and/or that is associated
with a relatively high risk of damage may be covered using
protective layer 40. Although TPE is described as one example
material that may be used to form protective layer 40, any material
that is resistant to dents, scratches, and does not create comfort
issues may be used to form protective layer 40. In some
embodiments, protective layer 40 may be formed from a material that
is softer and/or more pliable than shell 54.
[0019] In certain embodiments, separate pieces of protective layers
40 may be distributed to different portions of rim portion 34. For
example, as shown in FIG. 2, separate pieces of protective layers
40 are positioned at front left rim portion 34FL, front right rim
portion 34FR, rear left rim portion 34RL, and rear right rim
portion 34RR. This is advantageous in certain embodiments because
helmets having different sizes can be manufactured using protective
layers 40 having the same size, which simplifies the manufacturing
process. For example, regardless of the size of helmet 20, the
placement of protective layers 40 can be adjusted to accommodate
the different sizes of rim portions 34 by either being positioned
closer together (for smaller sizes) or farther apart (for larger
sizes).
[0020] Referring to FIG. 3, in certain embodiments, protective
layer 40 may be configured so that a portion of protective layer 40
extends further outwardly from body 50 than does shell 54, as
indicated by an arrow 70. This is advantageous in some embodiments
because the clam shell used to mold helmet 20 may bear down on the
protruding portion of protective layer 40, indicated by arrow 70,
to maintain the position of protective layer 40 during the molding
process.
[0021] FIG. 4 is a flowchart illustrating one embodiment of a
method 100 for providing protective layer 40 for helmet 20 shown in
FIGS. 2 and 3. Method 100 starts at step 104. At step 108, a clam
shell mold having a male side and a female side each defining a
portion of a chamber that has a shape of helmet 20 is provided. At
step 110, shell 54 is positioned in one side of the mold (typically
the female side, although this is not required) in a manner well
known to one skilled in the art. A suitable material, such as
polycarbonate plastic, may be used to form shell 54. Step 110 may
be omitted in some embodiments. At step 112, protective layer 40 is
positioned in desired locations of the mold. For example,
protective layer 40 is positioned in a male side of the clam shell
mold; however, in some embodiments, protective layer 40 may be
positioned in a female side of the clam shell mold. In certain
embodiments, step 112 may be performed before step 110 or in
conjunction with step 110. At step 114, a suitable material for
forming body 50 of helmet 20, such as EPS, may be provided into the
mold. For example, negative pressure may be created in the chamber
defined by the mold and EPS may be pressure-filled into the
chamber. At step 118, EPS in the chamber of the mold is heated to
form body 50 of helmet 20, thus in-molding protective layer 40 with
body 50 of helmet 20. EPS may be heated in any suitable method. For
example, EPS may be exposed to steam. In certain embodiments,
heating step 118 may be performed while performing step 114. Method
100 stops at step 120.
[0022] Although a helmet, such as helmet 20, is used as an example
device that may benefit from the teachings of the present
invention, any device that is molded out of a shock-absorbing
and/or insulation material, such as EPS, that is relatively easily
damaged may benefit from the teachings of the present invention.
For example, a portable cooler and a beverage holder formed from
EPS may benefit from the use of a protective layer to protect
against surface and body damage.
[0023] Although some embodiments of the present invention have been
described in detail, it should be understood that various changes,
substitutions, and alterations can be made hereto without departing
from the spirit and scope of the invention as defined by the
appended claims.
* * * * *